Structural cooling pack

ABSTRACT

A structural cooling assembly for a vehicle includes a housing defining a first pocket between a front face and a back face. The housing comprising a single integrated part including a fluid reservoir portion, a vane portion, a fan shroud portion, a bolster portion, and at least one mounting portion mountable to a frame of a vehicle. A condenser is mounted within the first pocket, a charge air cooler is mounted in a second lower packet, a fan assembly is mounted within the fan shroud portion and a radiator is mounted to the back face.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.16/524,234 filed on Jul. 29, 2019.

TECHNICAL FIELD

This disclosure relates to a front end structure for a motor vehicleincluding a fan disposed between a radiator and a condenser within anintegrated module.

BACKGROUND

The front end structure of a motor vehicles supports components such asa radiator, condenser, air induction components and latch assemblies.Space within the front end structure is limited and is challenge topackage all required components while also providing desired performanceand assembly efficiencies.

SUMMARY

A structural cooling assembly for a vehicle according to an exemplaryaspect of the present disclosure includes, among other things, a housingdefining a first pocket between a front face and a back face, thehousing comprising a single integrated part including a fluid reservoirportion, a vane portion, a fan shroud portion, a bolster portion, and atleast one mounting portion mountable to a frame of a vehicle, acondenser mounted within the first pocket, a fan assembly mounted withinthe fan shroud portion; and a radiator mounted to the back face.

In a further non-limiting embodiment of the foregoing structural coolingassembly, the housing includes a top portion and the fluid reservoir ispart of the top portion.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the top portion includes an air intake passagedefining a part of an airflow path to an air intake system of thevehicle.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the top portion extends from the forward face aftpast the back face and over a top of the radiator.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, a hatch latch assembly is attached within a latchpocket formed as part of the top portion.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the housing includes a washer fluid reservoirportion separate from the fluid reservoir portion, the washer fluidportion disposed partially within the top portion and a side portion ofone of the front face and the rear face.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, a conduit disposed within the washer fluid reservoirfor placing a hot flow in thermal communication with fluid within thewasher fluid reservoir.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the housing includes a second pocket defined belowthe first pocket between the front face and the back face and asecondary cooler is mounted within the second pocket.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the secondary cooler includes a bottom closure panelthat attaches to a bottom portion of the housing to provide structuralstiffness and close of a bottom opening of the second pocket.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the condenser includes a side closure panel thatattaches to a side portion of the housing to provide structuralstiffness and close off a side opening of the front pocket.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the vane portion comprises a first vane portiondisposed on the front face for directing airflow into the first pocketand a second vane portion disposed on the front face for directingairflow into the second pocket.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, at least one of the first vane portion and thesecond vane portion comprises an active grille shutter assembly

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the housing includes an integral horn trumpetportion within a side of one the front face and back face

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the fan shroud portion comprises a plurality of ribsextending radially outward from a fan mount portion.

In a further non-limiting embodiment of any of the foregoing structuralcooling assemblies, the housing is formed as a single integral part froma plastic material containing fiber reinforcement material.

A method of assembling a structural cooling assembly according toanother exemplary aspect of the present disclosure includes, among otherthings, forming a housing as single integral plastic reinforced partwith an additive manufacturing process to include a first pocket betweena front face and a back face, a degas chamber portion, a vane portion, afan shroud portion, a bolster portion, a horn trumpet portion and atleast one mounting portion mountable to a frame of a vehicle, mounting acondenser within the first pocket and attaching a side closure panel ofthe condenser to a side portion of the housing to provide structuralstiffness and close a side opening of the first pocket, mounting a fanassembly within the fan shroud portion and mounting a radiator to theback face to the back face such that the fan assembly is disposedaxially between the radiator and the condenser.

A further non-limiting embodiment of the foregoing method of assemblinga structural cooling assembly including assembling a secondary coolerinto a second pocket formed below the first pocket and attaching abottom closure panel of the secondary cooler to the housing to providestructural stiffness and close a bottom opening of the second pocket.

A further non-limiting embodiment of any of the foregoing methods ofassembling a structural cooling assembly including forming a washerfluid reservoir portion as an integral part of the housing separate fromthe fluid reservoir portion and assembling a conduit within the washerfluid reservoir portion for placing a hot flow in thermal communicationwith fluid within the fluid reservoir portion.

A further non-limiting embodiment of any of the foregoing methods ofassembling a structural cooling assembly including forming the housingto include a top portion with a latch pocket and mounting a hatch latchassembly within the latch pocket of the housing such that the housingstructure transfers latch loads to a frame of the vehicle.

The various features and advantages of this disclosure will becomeapparent to those skilled in the art from the following detaileddescription. The drawings that accompany the detailed description can bebriefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an example front end structure of a motorvehicle.

FIG. 2 is a front view of the example front end structure of a motorvehicle.

FIG. 3 is a front perspective view of an example structural coolingassembly.

FIG. 4 is a rear perspective view of the example structural coolingassembly.

FIG. 5 is a top sectional view of the example structural coolingassembly.

FIG. 6 is a perspective view of an example housing of the structuralcooling assembly.

FIG. 7 is a top view of the example housing of the structural coolingassembly.

FIG. 8 is a perspective view of an example mounting foot of the examplehousing.

FIG. 9 is a partial sectional view of the example mounting foot of theexample housing.

FIG. 10 is a partial sectional view of the example housing illustratingan integral washer reservoir portion.

FIG. 11 is a front perspective view of the example housing.

FIG. 12 is a rear perspective view of the example housing.

FIG. 13 is a rear view of the example housing with a fan assemblymounted within a shroud portion.

FIG. 14 is a schematic view of an example assembly sequence of thestructural cooling assembly.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2 , a front end structure 12 of a motor vehicleis shown with an example structural cooling assembly 26. An engine 16,transmission 22, air induction system 18 and compressor 20 areschematically shown proximate the front end structure 12, front vehiclefacia 25 and the structural cooling assembly 26. The structural coolingassembly 26 includes components that support operation of vehiclesystems as well as providing a structural part of the front endstructure 12. The disclosed example structural cooling assembly 26includes a one piece housing 28 to which are attached a radiator 64, acondenser 62, a charge air cooler 68 and a fan assembly 66. Thestructural cooling assembly 26 provides a single modular assembly thatincorporates multiple components that support operation of differentvehicle systems while also providing a structural part of the vehicle.

The radiator 64 includes an inlet 76 and outlet 78 to provide a coolantflow to the engine 16. The condenser 62 is coupled to a refrigerantcircuit 20 for an environmental control system of the vehicle 10. Thecharge air cooler 68 cools air provided to the air induction system 18.It should be appreciated that although a charge air cooler 68 isdisclosed by way of example, other secondary coolers such as an oilcooler, transmission cooler or any other cooler could also be utilizedand are within the contemplation of this disclosure.

The housing 28 includes a first pocket 34 defined between a front face30 and a back face 32. The first pocket 34 defines a space for thecondenser 62. A second pocket 36 is provided below the first pocket 34between the front face 30 and the back face 32. The charge air cooler 68is supported within the second pocket 36. The second pocket 36 may bespace open to the first pocket 34 or a separate space defined separatefrom the first pocket 34.

The housing 28 includes mounting portions that define attachment pointsto the vehicle frame 14 and bolster 24. The housing 28 further includesa location for a hood latch assembly 72 to secure a vehicle hood 15.

Referring to FIG. 3 with continued reference to FIGS. 1 and 2 , thehousing 28 is a single unitary integral structure that provides featuresthat are typically provided as separately mounted components. In thisdisclosed example, the housing 28 includes a top portion 38 with a latchpocket 70, degas reservoir 46 and an air passage 80. The housing 28transfers latch loads through the structural cooling assembly 26 to thevehicle frame 14.

The front face 30 includes first and second vane assemblies 58, 60disposed above and below a bolster portion 52. The vanes 58, 60 may bepassive fixed vanes or part of an active grill shutter assembly thatmoves the vane assemblies 58, 60 to adjust airflow. In one disclosedembodiment, the active grill shutter assembly includes a drive link bar74 that is coupled to an actuator 57 for moving the vanes 58, 60. Thedrive link bar 74 is coupled to a pivot housing 75 for moving the vanes60. When opening the first vane assembly 58 with the actuator 57, thedrive link bar 74 drives and opens the second lower vane section 60. Theactuator 57 is controlled to adjust flow through the housing 28.

The bolster portion 52 corresponds with the bolster 24 of the vehicle 10and may be oriented and shaped to accommodate different vehicleconfigurations.

The housing 28 further includes integral horn trumpets 50. The horntrumpets 50 are supported on each of the first side 40 and the secondside 42. The horn trumpets 50 support sound producing devices thatcooperate with the size and shape of the integrated horn trumpets 50 toprovide a predefined tone. The sound producing device is not shown butmay be any device that is actuatable to generate a sound and is mountedto the housing into and/or proximate the trumpets 50.

Referring to FIG. 4 with continued reference to FIG. 3 , the back face32 of the structural cooling assembly 26 is shown with the radiator 64attached to the housing 28. An outlet 82 of the air passage 80communicates airflow to the vehicle air induction system 18 (FIG. 1 ).Mounting feet 56 along with mounting flanges 54 are integral portions ofthe housing 28 and transfer weight of the structural cooling assembly 26to the vehicle frame while also contributing to the structural stiffnessof the front end structure 12.

An inlet 86 and an outlet 88 for the charge air cooler 68 face vehiclerearward and on either side of the radiator 64. The inlet 86 and outlet88 accommodate attachment of ducts to communicate airflow required foroperation of the charge air cooler.

Referring to FIG. 5 with continued reference to FIGS. 1 to 4 , the topportion 38 is shown partially cut away to show the air passage 80 andthe degas reservoir 46. The air passage 80 directs airflow from aforward inlet 84 to an aft outlet 82. The air passage 80 directs airflowthrough the housing 28 to the air induction system 18 (FIG. 1 ).

The degas reservoir 46 is formed within the top portion 38 and adjacentthe air passage 80. The degas reservoir 46 is in fluid communicationwith the engine cooling system. It should be appreciated that the degasreservoir 46 may extend further within sides 40, 42 of the housing 28 toprovide a predefined fluid capacity.

The latch pocket 70 provides a mounting location for the latch assembly72. A tube 77 extends from latch pocket 70 through the degas reservoir46 and out a side of the housing 28. The tube 77 is sealed off from thedegas reservoir 46 to enable a latch cable 79 to be routed to the latchassembly 74. Incorporation of the tube 77 effectively hides the latchcable 79 to provide an enhanced aesthetic under hood appearance of thefront end structure 12.

Referring to FIGS. 6 and 7 , the example housing 28 includes a fanshroud portion 95 within which the fan 66 is mounted. The shroud portion95 circumscribes an interior space for the fan 66. A fan mount ring 94is supported by a plurality of radially extending support ribs 96. Themount ring 94 is within the housing 28 such that the fan can be mountedbetween the radiator 64 and the condenser 62. The front face 30 of thehousing 28 is shown in FIG. 6 . The fan 66 is mounted to the back face32.

The top portion 38 includes the latch pocket 70 for the latch assemblyand filler openings 90 and 92. The filler opening 90 is for the degasreservoir 46 and the filler opening 92 is for the washer fluid reservoir48.

Referring to FIGS. 8 and 9 , the mounting feet 56 are integralstructures of the housing 28. The mounting feet 56 include internalstiffening ribs 55. The example housing 28 is formed utilizing anadditive manufacturing process that enables formation of internalstructures, such as the internal stiffening ribs 55, not practical withtraditional injection molding processes. The stiffening ribs 55 areinternal structures not visible in the completed housing 28 as shown inFIG. 6 .

Referring to FIG. 10 , the housing 28 includes the interior opencompartment that forms the washer fluid reservoir 48. The washer fluidreservoir 48 is disposed in one side 40 of the housing 28. The degasreservoir 46 is in the other side 42.

The hollowed sides 40, 42 include rib structures that provided apredefined rigidity to the housing 28. In this disclosed example,radially extending ribs 104 extend from a circumferential internal rib108. The circumferential rib 108 corresponds with the fan shroud 95 thatcircumscribes the opening for the fan. A curved longitudinal rib 106 isprovided on either side of the fan opening to provide additionalrigidity. The rib structure is possible by the additive manufacturingprocess utilized for manufacture of the housing 28.

A conduit 98 is supported within the washer fluid reservoir 48. Theconduit 98 is in communication through inlet 100 and outlet 102 with asource of hot fluid flow. In this example, the hot fluid flow is from acooler for a transmission 22. However, other hot fluid flows, such ascoolant from the radiator 64, may also be utilized. The conduit 98places a hot fluid flow in communication with the washer fluid withinthe reservoir 48. The washer fluid is thereby heated to an elevatedtemperature.

Heated washer fluid is useful in colder climates to aid in theelimination of ice and snow build up on a windshield or rear window. Acontrol system is utilized to govern hot fluid flow and thereby atemperature of the washer fluid. The inlet 100 and outlet 102 areintegrally formed as part of the housing 28. Moreover, the conduit 98may be formed as an integral part of the housing 28, or assembled as aseparate part within the reservoir 48.

Referring to FIGS. 11, 12 and 13 , the housing 28 is shown with the fanassembly 66 (FIG. 13 ) installed with a fan motor 110 supported withinthe fan mount 94. The housing 28 defines the first pocket 34 for thecondenser 62 between the front face 30 and the back face 32. The secondpocket 36 is defined below the first pocket 34 between the front face 30and the back face 32. The first and second pockets 34, 36 includeinternal features and guides for supporting the condenser 62 and thecharge air cooler 68. The pocket 34 is open to side opening 35 on theside 40. The first pocket 34 is closed on the side 42. The bottomportion 44 includes a bottom opening 37 that leads into the secondpocket 36. Closure panels (FIG. 14 ) on each of the condenser 62 and thecharge air cooler 68 attach to the housing 28 to secure each componentand close off the corresponding one of the first and second pockets 34,36.

Fan blades 112 rotate within the fan shroud 95 and pull air through thefront face 30 and out the back face 32 and the radiator 64. The housing28 defines the flow path for air through the fan blades 112 to create anefficient use of cooling air.

Referring to FIG. 14 , a disclosed method of assembling a structuralcooling assembly 26 is schematically shown. The method begins withformation of the housing 28 utilizing an additive manufacturing processschematically shown at 120. The example additive manufacturing processutilizes a reinforced plastic material 122. In this example, reinforcedplastic material 122 is polyamide plastic material that is reinforcedwith 35% carbon fiber reinforcement. It should be appreciated that otherplastic materials and combinations of reinforcement materials andquantities could be utilized and are within the contemplation and scopeof this disclosure.

The additive manufacturing process 120 deposits layers of molten plasticmaterial 122 that subsequently harden to form layers of the housing 28.Each layer is deposited in sequence on previous layers to form internalstructures and features of the housing 28. The layer by layer build upenables formation of internal structures such as the ribs 104, 106within the reservoirs 46, 48 (FIG. 10 ). Moreover, the additivemanufacturing process enables formation of the internal support ribsprovided within the mounting feet (FIGS. 8, 9 ).

Once the housing 28 if formed as the single integral part, componentsare assembled and attached to form the structural cooling assembly 26.In this example, a side closure panel 116 is attached to the condenser62. The condenser 62 is then inserted into the first pocket 34 and theclosure panel 116 secured to the side 40 of the housing 28 as is shownat 125. The side closure panel 116 secures the condenser 62 and sealsthe first pocket 34.

A bottom closure panel 114 is attached to the charge air cooler 68. Thecharge air cooler 68 is then inserted into the second pocket 36 throughthe bottom opening 37. The bottom closure panel 114 is then secured tothe bottom portion 44 of the housing 28.

The fan assembly 66 is then mounted to the fan shroud portion 95 on theback face 32 as shown in FIG. 13 . The radiator 64 is then assembled andsecured to the back face 32. Accordingly, the fan assembly 66 isdisposed within an axial space between the condenser 62 and the radiator64. The latch assembly 72 is then assembled into the latch pocket 70.

The assembled structural cooling assembly 26 provides a single modulewith the proper spacing between the condenser 62, radiator 64 and thefan assembly 66. The assembled structural cooling assembly 26 furtherincludes the integral features such as the degas reservoir 46,windshield washer fluid reservoir 46 and horn trumpets that areintegrated as parts of the housing 28. The structural cooling assembly26 may then be assembled as a single unit into a vehicle and secured inplace to become a structural component of the vehicle front endstructure 12.

Although the different non-limiting embodiments are illustrated ashaving specific components or steps, the embodiments of this disclosureare not limited to those particular combinations. It is possible to usesome of the components or features from any of the non-limitingembodiments in combination with features or components from any of theother non-limiting embodiments.

It should be understood that like reference numerals identifycorresponding or similar elements throughout the several drawings. Itshould be understood that although a particular component arrangement isdisclosed and illustrated in these exemplary embodiments, otherarrangements could also benefit from the teachings of this disclosure.

The foregoing description shall be interpreted as illustrative and notin any limiting sense. A worker of ordinary skill in the art wouldunderstand that certain modifications could come within the scope ofthis disclosure. For these reasons, the following claims should bestudied to determine the true scope and content of this disclosure.

What is claimed is:
 1. A structural cooling assembly for a vehiclecomprising: a housing including a front face, a back face and a topportion, the housing comprising a single integrated part including afluid reservoir portion, a fan shroud portion, a bolster portion, an airintake passage defining a portion of an airflow path through the topportion of the housing to an air intake system of the vehicle and atleast one mounting portion mountable to a frame of a vehicle; and a fanassembly mounted within the fan shroud portion.
 2. The structuralcooling assembly as recited in claim 1, wherein the housing includes thefluid reservoir is part of the top portion.
 3. The structural coolingassembly as recited in claim 2, including a radiator mounted to the backface.
 4. The structural cooling assembly as recited in claim 3,including a hatch latch assembly attached within a latch pocket formedas part of the top portion.
 5. The structural cooling assembly asrecited in claim 3, wherein the housing includes a washer fluidreservoir portion separate from the fluid reservoir portion, the washerfluid portion disposed partially within the top portion and a sideportion of one of the front face and the rear face.
 6. The structuralcooling assembly as recited in claim 5, including a conduit disposedwithin the washer fluid reservoir for placing a hot flow in thermalcommunication with fluid within the washer fluid reservoir.
 7. Thestructural cooling assembly as recited in claim 1, wherein the housingincludes a first pocket and a second pocket, a condenser mounted withinthe first pocket and a secondary cooler is mounted within the secondpocket.
 8. The structural cooling assembly as recited in claim 7,wherein the secondary cooler includes a bottom closure panel thatattaches to a bottom portion of the housing to provide structuralstiffness and close of a bottom opening of the second pocket.
 9. Thestructural cooling assembly as recited in claim 8, wherein the condenserincludes a side closure panel that attaches to a side portion of thehousing to provide structural stiffness and close off a side opening ofthe front pocket.
 10. The structural cooling assembly as recited inclaim 9, wherein the housing further includes a first vane portiondisposed on the front face for directing airflow into the first pocketand a second vane portion disposed on the front face for directingairflow into the second pocket.
 11. The structural cooling assembly asrecited in claim 10, wherein at least one of the first vane portion andthe second vane portion comprises an active grille shutter assembly. 12.The structural cooling assembly as recited in claim 1, wherein thehousing includes an integral horn trumpet portion.
 13. The structuralcooling assembly as recited in claim 1, wherein the fan shroud portioncomprises a plurality of ribs extending radially outward from a fanmount portion.
 14. The structural cooling assembly as recited in claim1, wherein the housing is formed as a single integral part from aplastic material containing fiber reinforcement material.
 15. A methodof assembling a structural cooling assembly comprising: forming ahousing as single integral plastic reinforced part to include a front aback face, a fan shroud portion, a bolster portion, an air intakepassage forming a portion of an air intake path through a top portion ofthe housing to an air intake system and at least one mounting portionmountable to a frame of a vehicle; and mounting a fan assembly withinthe fan shroud portion.
 16. The method of assembling a structuralcooling assembly as recited in claim 15, further comprising mounting aradiator to the back face and a fan assembly such that the radiator isdisposed axially between the radiator and a condenser.
 17. The method ofassembling a structural cooling assembly as recited in claim 15, furthercomprising forming the housing to include a first pocket and mounting acondenser within the first pocket and attaching a side closure panel ofthe condenser to a side portion of the housing to provide structuralstiffness and close a side opening of the first pocket.
 18. The methodof assembling a structural cooling assembly as recited in claim 17,including assembling a secondary cooler into a second pocket formedbelow the first pocket and attaching a bottom closure panel of thesecondary cooler to the housing to provide structural stiffness andclose a bottom opening of the second pocket.
 19. The method ofassembling a structural cooling assembly as recited in claim 18,including forming a washer fluid reservoir portion as an integral partof the housing separate from a degas chamber portion and assembling aconduit within the washer fluid reservoir portion for placing a hot flowin thermal communication with fluid within the washer fluid reservoirportion.
 20. The method of assembling a structural cooling assembly asrecited in claim 19, including forming the housing to include a topportion with a latch pocket and mounting a hatch latch assembly withinthe latch pocket of the housing such that the housing structuretransfers latch loads to a frame of the vehicle.